TK42218 ACID/OREACID ORE SLURRY LINES RENEWAL YEAR 2016

4.0

SCOPE OF WORK

This specification shall be applicable for the scope related to the

replacement of the existing Acid/OreAcid Ore Slurry Lines. . The Contractor
shall carry out the following:4.0.1 Install new Acid/OreAcid Ore Slurry Lines and one 4 piping which is
connected to Hydroclones (215/024) like for like to the existing piping
including fittings, flanges, valves, gaskets, bolts and nuts. These materials
will be provided by HPAA. Refer Attachment 7.3 for details of Free Issue
Material.
4.0.2 Contractor shall Crepair or replace all pipe supports (approximately seven)
for AO Lines as in existing plant. Refer Attachment 7.8 for Site photos.
Contractor shall also apply maintenance painting for pipe supports. Refer
Attachment 7.6 for painting details.
ontractor shall carry out detail planning and job method in detail to reduce on
site fabrication and installation works. The job method shall be reviewed
by HPAA. Contractor shall make site measurements to verify the drawings
against the existing Acid/Ore Slurry piping installation. The contractor shall
access the site condition and verify if any other works is required to
complete the project and this shall be deemed included in this scope of
works unless otherwise explicitly mentioned in writing by HPAA.
4.0.32Repair or replace all pipe supports and apply maintenance painting for
pipe supports.Labelling for new piping including pipes, valves and
equipment. Refer attachment 7.5 for labelling details.
4.0.3 Labelling for new piping including pipes, valves and equipment. Refer 4.8
for labelling details.
4.0.4 Contractor shall ensure that the standard welding procedures as per ASME
code or equivalent are followed.
4.0.5 The item such as pipes, valves and fittings will be supplied by HPAA and
contractor shall carry out the installation. Contractor shall procure and
deliver all necessary direct and indirect material to carry out fabrication,
installation and tie in of the new pipeline to the existing pipeline. The
piping and fittings shall be free issued to the contractor by HPAA.
4.0.6 Contractor shall carry out the Non Destructive Testing as follows:
- Radiographic Testing (100% for Acid/OreAcid Ore Slurry Lines)
- Hydrostatic Test for Acid/OreAcid Ore Slurry Lines
- Dye Penetrant Testing (100% of fillet welds)
and Leak Test:
- Hydrostatic Test for Acid/OreAcid Ore Slurry Lines (shall be witnessed by
HPAA representative)
All test reports shall be endorsed by a HPAA representative.
4.0.7 The contractor shall access the site condition and verify if any other works
is required to complete the project and this shall be deemed included in
this scope of works unless otherwise explicitly mentioned in writing by
HPAA. Contractor shall verify the dimension on site and submit isometric
drawings before starting fabrication work and shall submit and submit
isometric drawings Approved for Construction (AFC) drawings for review
before and after replacement works. The final isometric drawing, as-built

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drawings and related documents shall be provided as final documentation
for the new piping installations.
4.0.8 Installation and checking works for Acid/OreAcid Ore Slurry Lines are
described below:
a) The existing Acid/OreAcid Ore Slurry Lines construction material is
stainless steel 316L of various schedule thicknedd. These need to be
replaced with material of stainless steel 316L schedule 80S pipes. Refer
attachment 7.43 (Pipe Spec R17) for further details.
b) All Fflange shields shall be cleaned and reinstall installed for all flanges
in Acid/OreAcid Ore Slurry Lines. LITMUS or PH paper shall be replaced if
necessary. Leakage at any flange is not acceptable after the replacement
of Acid/OreAcid Ore Slurry Lines.
c) The Contractor shall check and ensure a LEL level of 0ppm. This is to
ensure conditions are safe for hot work during removal of existing piping.
If LEL 0ppm is not achievable, cold cutting can only be performed by
approval of HPAA.
d) Checking works (in order to achieve LEL 0ppm) is required for existing
acid piping considering the fact that there may be residual acid left over in
the piping. If LEL 0ppm is not achievable, cold cutting shall be performed
by approval of HPAA. The scheduled waste that is generated during these
works needs to be disposed as per procedure.
e) Realignment and refurbishment of pump foundations if needed.
f) Contractor shall ensure the bolt of each joint (flange) of the Acid/OreAcid
Ore Slurry Lines need to be properly tightened with torque wrench. The
torque value for joint will be given by HPAA.
4.0.9 Contractor shall coordinate with HPAA in-house scaffolding contractor to
erect scaffolding at appropriate locations required to carry out the
installation works.
4.0.10Contractor shall prepare necessary lifting study for the lifts that are
required during the installation works and prepare the necessary cranes,
lifting equipment etc.
4.0.11Prepare the scope of work for other not listed but deemed necessary works
to be completed such as schedule waste management and housekeeping.

4.1

Engineering

4.1.1 The contractor shall be responsible to carry out the necessary engineering
design works required for the replacement of the existing piping. The
engineering and design activity shall include the following:
a) Replacement of Acid/OreAcid Ore Slurry Lines and one 4 piping
connected to Hydroclones (215/024) and align those piping and pumps
that had been replaced to the noozle/flange that are to be tie-in. Tie-in
point will be provided by HPAA and all flanges shall be covered with flange
shields. Refer drawings of aAttachment 7.1.

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b) Repairing, replacement and locate new pipe support location for new
piping if necessary. The design of new pipe support shall be like to like for
existing pipe supports.
c) All new piping and non-piping elements are to be installed with new
connection accessories (plates, angles, nuts, bolts, washers, etc.).
4.1.2 The contractor shall propose the suitable painting adhesive tape material
to be used in a corrosive/acidic environment for labelling. Contractor shall
provide engineering justification for the selected painting adhesive tape
material to be used for the new piping.
All
painting
labelling
specifications are to comply with Attachment 7.5. 7.4 Specification for
Painting in Malaysia (MA.23.02.00). Refer attachment 7.1 for mark-up.
Blasting and pPainting works are required for new all pipe supports. Refer
to sectionAttachment 7.64 for Blasting, Painting and Surface Preparation
for details.
4.1.3 The contractor is to ensure the overall safety of the working area is
maintained during the entire course of the replacement works. The
contractor is to submit isometric drawings for review before and after
replacement works.
4.1.4 The contractor shall supply suitable Project Management Team (Project
Manager, Planner/Scheduler, Project Engineer, Site Supervisor, QA/QC
Engineer, Safety Officer) manpower, tools, equipment, and consumables.

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4.2

Procurement

4.2.1 For the Equipment and Materials that to be provided by the Contractor
a) Unless clearly defined as supplied by the Client, Engineer or Project
Manager then all materials are the responsibility of the Contractor to
supply.
b) In order to demonstrate that the Contractor is ordering materials for
incorporation in the permanent works in a timely manner he will
supply one un-priced copy of his purchase order (complete with all
attachments) to the HPAA within 7 days of the order being
committed. The Contractor will also supply Procurement Status report
on a weekly basis against all materials required for the permanent
works that is in his remit to supply.
c) Materials Selection & Supply
The individual Material Specifications generally permit the Contractor
to select items from a range of acceptable Manufacturers/ Model No
via the submittal approval system. To ensure operational spares
holding requirements on site are maintained at reasonable levels,
once a particular item type is selected that selection shall be used
throughout the Site and any change to that selection shall only be
with the approval in writing of the HPAA. Definition of item type
shall be at the reasonable discretion of the HPAA.
4.2.2 For the Equipment and Deliverables that to be provided by the Project
Manager
Wherever applicable free Issue materials to be provided by the HPAA will
be issued from the site specific warehouse, the Contractor is to make
provision to requisition, transport and offload these materials at his place
of work.
4.2.3 Reports to be provided by the Project Manager
Wherever applicable, HPAA will provide on a regular basis a Materials
Management System (MMS) report detailing the status of materials to be
provided by him. The MMS report details the status of orders from
placement through to delivery on-site and will allow the Contractor to plan
his worked based on the information provided.

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4.3

Material

4.3.1 Except where it is expressly specified in the Work Order that the Materials
or part thereof are to be provided by HPAA, the contractor shall provide all
Materials necessary to perform and complete the WORK.
4.3.2 All Materials supplied by the contractor in the performance of the WORK
shall be in accordance with HPAA TECHNICAL SPECIFICATIONS,
INTERNATIONAL CODES and STANDARD , HPAA PROCEDURES, relevant
and CONTRACT and DRAWINGS.
4.3.3 All Materials supplied by the contractor for incorporation into the WORK
shall be new, free from defects and fit for their intended purposes.
Materials incorporated into the WORK shall be traceable to certificates.
The grades of certificates (accordance with ASME standard) shall be
determined by the contractor and agreed to by HPAA for different types of
Materials.
4.3.4 HPAA reserves the right to accept or reject any Materials and demand
removal of any rejected Materials or Materials found defective from the
Work Site. Replacement of rejected Materials or rectification of defects or
inherent damage to Materials shall be for the contractors account.
4.3.5 The contractor shall provide the required procurement for all contractors
supplied Materials.
4.3.6 The contractor shall provide all Materials and consumable required for preproduction activities such as weld procedure and welder qualification and
testing at no additional cost to HPAA.
4.3.7 The mill certificate for all the material is required to submit to HPAA for
verification. Where original copies of mill certificates cannot be obtained,
such as in the case of ex-stock materials, the photocopies of the mill
certificates shall be certified.
4.3.8 Contractor shall not accept Materials without the required documentation
and test certificates. HPAA reserved the right to reject any and all
Materials not meeting this requirement.
4.3.9 Contractor shall have full responsibility for management, scrapping and
storage of its surplus Materials.
4.3.10The contractor shall take receipt of Materials issued by HPAA and
thereafter the contractor shall be responsible for the safekeeping and
proper utilisation of these Materials.
4.3.11The contractor shall maintain adequate records of all Materials supplied by
HPAA as well as the place and method of utilization. Such records shall be
in a form acceptable to HPAA.

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4.3.14The contractor shall be responsible for the disposal of all waste materials
from the WORKSITE. The procedures, methods and facilities regarding
waste disposal shall be approved by HPAA representative.
4.3.15All materials used to be aligning with drawing and material at HPAA.
4.3.16All materials used shall be approved by HPAA and shall provide with
manufacturing data certificate. The Positive Material Identification (PMI)
shall be carried out if needed by the employer and the cost for conducting
the PMI shall be borne by the contractor.
4.3.17All the structure steel components shall be like for like replacement as per
stated in the provided drawing or been specifically stated in the BOQ.
4.3.18For any insert plate used or new structure steel, the mill certificate shall
be handover to project manager for verification and equivalent with
existing structure steel. Materials from Japan and Europe are preferred.
4.4

Staff, Establishment and Common user Facilities

4.4.1 Organization Requirements

An Organisation Chart shall be submitted and include the following details:
a) Identification of full-time/ part-time employees and subcontractors.
b) Identification of where they are based i.e. home office, site or both
(and, therefore percentage split between office and site).
4.4.2 Supervisory Requirements
The contractor should ensure that the ratio of non-working supervisory
staff and safety advisors be equitable to the requirements of the Project.
Similarly he should ensure that the levels of supervision employed within
any sub-contract arrangements be of the same level.
4.4.3 Accommodation and Storage
Areas for the establishment of offices, mess/drying and storage units on
site have been set out. Contractors tendering are to provide a detailed
plan showing their proposed ergonomic and aesthetic site establishment,
including an estimate of area and utilities required. It is likely that storage
for equipment, small tools and consumables will be in the footprint of the
construction area, Contractors tendering are to ensure that they include
for site storage facilities in this area also and fully consider any impact
that this might have on their day to day operations.

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4.4.4 Welfare Facilities
The contractor is to provide in totality workers canteen, messing and
drying facilities for all his operatives, including transport off and onto site
at all start, finish and break times ensuring no additional costs or delay is
incurred by this requirement, the HPAA has Contractor Canteen Facility for
a communal dining area, however this does not mitigate the contractors
responsibility to provide Worker welfare. Toilet facilities can be used within
the related working area and additional toilet facilities will not be provided
in any other area. The contractor should ensure that he makes due
allowance for this situation within his Tender.
4.5

Planning & Progress

4.5.1 Planning
The following describes the expectations of the HPAA in respect of the
capabilities of the appointed contractor in being able to plan, progress and
report his work. The capabilities of the Tenderer should be demonstrated
by his tender submission. The Contractor will be required to provide a
detailed Construction Schedule showing the sequence and time-span of all
the activities required to execute the works. The schedule must fall within
the time-scale and parameters mentioned in the CONTRACT. All activities
on the schedule must be populated with agreed Construction man hours.
The Construction schedule must be fully logic-linked. The amount of
Activities with Constraints must be kept to a minimum. The contractor
shall ensure that full account is taken of factors such as interfaces, tender
milestones; forecast deliveries of free-issue material and the
forecast
lead times a delivery of own-supply materials. The contractor shall make it
clear in the schedule which holiday periods he will not be working. The
contractor shall provide:
a) A general description of the arrangements, sequence and methods of
Construction (which illustrates the contractor's intent) which the
contractor proposes to adopt for the carrying out of the works.
b) A Manpower Programme and Histogram to reflect the Construction
Schedule's man hours showing on a week by week basis and for each
trade or craft the number of personnel who will be engaged in the
Works. This should include all offsite activities e.g. pre-fabrication etc.
c) The Histogram should distinguish between Staff and tradesmen. A
Planned "S-Curve" (from the Construction Schedule) showing the
Planned/ Target progress of the works over the time-span of the
works.

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4.5.2 Progress Reporting
The Project will demand Weekly Progress Reporting. The weekly Progress
Reports should consist of the following: a) A brief "Bullet Point" narrative describing present Progress and
Productivity and All Negative Float activities, Manpower and Materials
status together with highlighting Problem Areas and any possible
future punch or Hold Points and Proposed Corrective action to
mitigate possible delays.
b) Progress S- Curve
This report should show Planned V's Actual Man Hours achieved on a
percentage basis against the Baseline man hours. The report should
accommodate figures and graph both on a weekly and cumulative
basis. This report shall also include Planned Vs Actual Quantities
curves for Key Progress Indicators.
c) Site Progress Report
This report shall contain each activity on the Contract Programme
and shall show Planned V's Actual Percentage complete and manhours earned for each activity. The report should also show the
Planned Early Start and Finish dates and the Revised Start and Finish
dates for each activity once the programme has been re-scheduled
using the revised Data date. All Actual Start and Finish dates must
also be recorded on the schedule report. Each package of the works
on this report should be capable of being rolled -up to give an overall
assessment per area or trade.
d) Site Manpower Report
This report shall list the Contractors site manpower by trade and
show the actual number of people for the Contractor (and all subcontractors under his control) on site for each trade for each day of
the week as well as the total man days and man hours for both.
e) Material Report
This report should
Contractor's supply.

track

the

status

of

materials

within

the

4.5.3 Timing and Agreement of Report

The Contractor will agree with the HPAA the date and time for the
submission of his report. Prior to the Progress Meetings the report will be
agreed and signed off by the Project Manager
4.5.4 Progress Meeting

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Progress meetings will be held every week between the HPAA and the
Contractor.

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4.5.5 Schedule Opportunity
HPAA are always keen to explore ideas that could help in reducing the
schedule durations. The Tenderer should highlight any potential savings
for consideration and any design changes and/ or cost effect that would be
brought about by incorporation of those changes.
4.6

Construction

4.6.1 The contractor shall fabricate, install, inspect and test pipework in
accordance with HPAA TECHNICAL SPECIFICATIONS, INTERNATIONAL
CODES and STANDARD HPAA PROCEDURES, SPECIFICATIONS, CODES &
STANDARDS PROCEDURES and related the DRAWINGS. Should the
contractor deviate from this, a formal request is to be submitted, reviewed
and approved before decommissioning of piping. The contractor is
required to carry out site verification prior fabrication for lines without
isometric drawing.
4.6.2 The contractor is to keep the work site and immediate surrounding areas
clean and tidy at all times. Storing of construction materials and
equipment and construction waste and debris generated are to be
managed properly and kept in the designated area. The contractor is to
submit his proposed construction layout plan and scheduled waste
management programme /system for review and approval.
4.6.3 The contractor is to submit his proposed JMS for the replacement works,
complete with all the necessary documentation and endorsements as
stated in item 4.1.
4.6.4 The contractor shall carry out site measurements for item 4.1.1, 4.1.2 and
4.1.3. The contractor shall perform all checks, measurements and tests
required by HPAA to ensure proper installation and alignment of pumps,
piping, valves and fittings.
4.6.5 Additionally, the responsibility of the contractor shall include, but not be
limited to the following:a) Transportation and safekeeping of all piping Material.
b) Fabrication, installation, and pressure testing of all pipework, fittings,
and fabrication of supports as required.
c) Colour code marking or labelling for identification of all pipework,
valves, equipment and supports.
4.6.6 Specifications for piping Material, line classification, line numbering, valve
types, branch reinforcement, and miscellaneous piping requirements,
including but not limited to galvanising or pickling where required prior to
installation, shall conform to - SPECIFICATIONS, CODES & STANDARDS

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PROCEDURES.HPAA TECHNICAL SPECIFICATIONS, INTERNATIONAL CODES
and STANDARD HPAA PROCEDURES.
4.6.7 Prior to flanging, the inside of each pipe section shall be checked for
foreign matter and adequately cleaned by the use of leather or canvas
belt discs of proper diameter or by other methods approved by HPAA.
4.6.8 The contractor shall supply Equipment and/or Material as required,
fabricate, assemble and inspect structural steelwork, in accordance with
SPECIFICATIONS, CODES and STANDARD PROCEDURES and the
drawings.HPAA TECHNICAL SPECIFICATIONS, INTERNATIONAL CODES,
STANDARD HPAA PROCEDURES and drawings.
4.6.9 The contractor shall supply all temporary materials required for fabrication
purposes such as erection aids, supports, and etc.
4.6.10

The contractor needs to store all the dismantled equipment, piping,

structure and etc. to avoid any defect during dismantling and storing.

4.6.11

The contractor needs to do touch up paint on the structure if the is

scratch while handling those structures. The contractor also need to paint
back bolting when re-install the structure. The contractor needs to refer to
the Aattachment 7.64 for Specification for Painting in Malaysia
(MA.23.02.00) for structure paint maintenance.

4.6.12

The contractor needs to disconnect and reconnect back all electrical

and instrumentation equipment such as control valve, motor and gear box,
lighting or etc. that is required to complete this project. The contractor
shall prepare the scope of work for electrical and instrumentation work.
HPAA will give necessary assistant upon completion of this job.

4.6.13All structural steel surface preparation and painting works are to be done
off-site and finished product be brought to site. If there is requirement for
on-site surface preparation works and painting works proper
documentation and justification to be submitted to the Project Manager for
review and approval.
4.6.14All Mechanical and Electrical works (piping, wiring, etc.) that are
obstructing the works are to be checked and temporarily terminated or
relocated for the duration of the project. Contractor is to submit the JMS
for the proposed termination or relocation to the Project Manager and
HPAA Area Engineer for review and approval before proceeding.

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4.7

Procedure

4.7.1 The contractor shall prepare fully detailed procedures for each and every
operation to be performed. These individual procedures shall fall into the
following categories
a) Work mode/ construction.
b) Material Control, Movement, Handling, Inventory, Storage and
Certification - Both contractor and
c) HPAA supplied.
d) Maintenance/ Service of Equipment.
e) Testing and Certification of Equipment.
f) Personnel Mobilization and Demobilization.
g) Medical and Safety
h) Administration.
i) Anti-Pollution and Waste Control/ Disposal.
j) Quality Assurance and Quality Control.
k) Specific construction procedures
l) Other procedures as and when required by HPAA
m) Each individual procedure that falls under the above categories shall
address
i)
Objectives.
ii)
Requirement.
iii)
Responsible Persons/ Lines of Authority/ Interfaces.
iv)
Implementation.
v)
Participation.
vi)

Emergency and Remedial Actions

4.7.2 Due regard shall be paid to statutory regulations and/ or HPAA

specifications, codes of practice, HPAA TECHNICAL SPECIFICATIONS,
INTERNATIONAL CODES and STANDARD HPAA PROCEDURES, good
practice, and the like.
4.7.3 It is anticipated that the matters to be the subject of defined procedures
will be exhaustive.
4.7.4 Each procedure shall be prepared and submitted for the approval of HPAA.
The procedures shall not be implemented until HPAA has informed the
contractor that they have no further comments, suggestions or
requirements. In view of the above it will be expected by HPAA that all
required procedures will be ready for review and submitted to HPAA
immediately after CONTRACT award so that they can be approved by HPAA
and implemented prior to the mobilization of the construction personnel
and Equipment.
4.7.5 Any waiver by HPAA of the above or HPAA involvement or non-involvement
in the preparation of procedures, including commenting, making
suggestions, instructing requirements, and the like, shall not remove or
affect any responsibility of the contractor under the CONTRACT or the
performance of the WORK by the contractor.
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4.8

Blasting, Painting and Surface Preparation

4.8.1 The contractor shall refer to the Aattachment 7.64 for Specification for
Painting in Malaysia (MA.23.02.00).
4.8.2 Application requirements:
a) No paint shall be applied to any surface until it has been cleaned and
prepared in accordance with the specification. All surfaces must be
dry and free from dust, oil or grease before paint is applied.
b) Coated surfaces shall be clean and free from all grease or oil before
further coats are applied. Cleaning procedures for contaminated
coated surfaces are applied. Cleaning procedures for contaminated
coated surfaces are to be approved by HPAA representative.
c) Paint shall not be applied to wet surfaces, or when it is raining, or
when the relative humidity exceeds 90%. Day to day measurement of
relative humidity shall be examined by certified Painting Inspector.
d) The manufacturers recommendations for storage and preparation of
materials shall be complied with. Materials stored for longer than the
specified shelf-life shall not be used. Mixed two-pack systems shall
not be used after the specified pot life.
e) Paint shall be applied strictly in accordance with the manufacturers
specification. In particular, drying times will not be less than those
specified by the manufacturers, and if required, not greater than the
maximum permissible period before re-coating.
f) Thinners shall not be used unless approved by the paint
manufacturer and HPAA.
g) All operators should be skilled and experienced in the method used
and the supervisor should be skilled in each method under his
control.
h) All coating material shall be applied uniformly to produce an even
coating with a good cosmetic appearance (e.g. no drips, runs or
bubbles). The coating thickness shall be maintained on corners,
edges, etc.
i) Paint dry film thickness shall be measured using a suitable
instrument in accordance with BS. 3900 Part C5. Over any square
meter of a schedule area the average of the readings taken should
equal or exceed the nominal thickness given in the system
specification, and in no case should any reading be less than 75% of
the nominal thickness. (BS 5493 Para. 19)
j) Particular care should be taken in handling and storage of painted
items to avoid damage to the coating. Damage areas shall be
repaired using a system appropriate to the extent of damage.
k) The contractor shall appoint Certified Painting Inspector. Surface
preparation and painting will be inspected by Certified Painting
Inspector and witnessed by HPAA representative. The levels of
inspection will be intermittent or occasional (as define in BS5493
Para 37) depending on the nature of the work. The inspection level
will be defined in the order specification. Inspection report shall be
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prepared by the Certified Painting Inspector by daily, weekly and
monthly during paint application, test and commission.

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l) Surface preparation and painting shall be performed safely and
hygienically. All local health and safety regulation shall be complied
with. Care shall be taken to ensure the health and safety of all other
personnel in the work area, as well as the operatives. Work places
shall be kept clean and tidy.
m) To inform the HPAA representative(s) to witness all the inspection
those are going to be carried out by the contractor. The inspection is
under contractors scope and the contractor shall submit the blasting
and painting detail report done by Certified Painting Inspector.
n) The contractor to prepare and to submit the Safe Work Method
Statement (SWMS) and Hazards Identification, Risks Assessment and
Risks Control (HIRARC)
before carrying out any job. For the
inspection, the contractor shall provide a detailed Inspection Plan
which will need to be approved first by HPAA Project Manager,
especially those activities related to working at height, near to
explosion area, acid pipe area, etc.
o) The permit to operate (PTO) for abrasive blasting activities shall be
endorsed by DOSH prior to execute the work. The contractor has to
submit the letter of approval to Project Manager for record keeping.
4.9

Scaffolding erection

4.9.1 Scaffolding is under management of HPAAawarded contractor and

contractor shall coordinate with must hire internal HPAA in-house
scaffolding contractor.
4.9.2 The contractor shall advice the scaffolding contractor on the manner of
the erection.
4.9.3 Contractor shall submit the quotation estimation of scaffold volume that
needed for scaffolding erection for the whole project.
4.9.4 Contractor shall ensure the activity of scaffolding follow the standard as
attached in EHS guidelines. Any modification extended from the standard
of erection need to be endorsed by competence engineer.
4.9.5 Scaffolding shall be up to British Standard (BS) and HPAA standard. The
successful contractor shall engage only certified and appointed in-house
scaffold erectors for all scaffolding works on site. Contractor shall hire
qualified inspector to inspect the erected scaffolding.
4.10 Maintenance of the work
The contractor shall at the contractors cost make good and repair with all
due diligence any and all defects in the WORK and the consequences
thereof due to faulty or poor design, workmanship or material for which
the contractor is responsible and which become apparent within a
maintenance period duration.
4.11 Quality Assurance
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4.11.1The contractor shall conduct a continuous programme of quality assurance
to ensure all WORK performed conform in all respects with their
requirements of the CONTRACT.
4.11.2The contractor shall develop and submit to HPAA for review within
fourteen (14) days of the Effective Date of CONTRACT, a Quality Assurance
(QA) manual and Quality Control (QC) manual in accordance with the
requirements of ISO 9002. Subject to approval by HPAA an equivalent
standard ISO 9002 may be used. A guideline of the Quality Assurance
Programme requirement can be obtained from HPAA.
4.11.3HPAA review and approval of the contractors QA/ QC Manual shall not
relieve the contractor of any of its responsibilities under the CONTRACT.
4.12 Inspection, Testing and Commissioning
4.123.1
Any and all provision under this Inspection, Testing and
Commissioning shall be supplied and equipped by contractor at its own
cost and all such costs shall be included in the prices and rates in SCHEDULE OF COMPENSATION.
4.132.2
All inspections and testing shall be done in accordance with
SPECIFICATIONS, CODES and STANDARD PROCEDURES.HPAA TECHNICAL
SPECIFICATIONS,
INTERNATIONAL
CODES
and
STANDARD
HPAA
PROCEDURES.
a) All WORK packages shall be inspected, tested and commissioned (as far
as HPAA deems it to be practical) at the Work Site.
b) The contractor shall arrange for and carry out all inspection, testing and
commissioning in accordance with the CONTRACT. The contractor shall
provide for third party inspection to ensure that all contractor supplied
consumables and Equipment and Materials conform to the codes detailed
in SPECIFICATIONS, CODES and STANDARD PROCEDURES. HPAA
TECHNICAL SPECIFICATIONS, INTERNATIONAL CODES and STANDARD HPAA
PROCEDURES. The contractor shall provide at the WORKSITE full facilities
for the radiographic and ultrasonic inspection of welds, including, films,
radiographic and ultrasonic equipment, dark room equipment for
development of films, viewing facilities and a full time services of NDT
technicians, qualified in accordance with the specifications and fully
conversant with radiographic, ultrasonic and any other inspection
techniques required for the completion of the WORK in accordance with
CONTRACT.
c) The cost of providing inspection and testing facilities pursuant to this
Clause shall be included in the unit rates in accordance with - SCHEDULE
OF COMPENSATION. d) The contractor shall also provide at the Work Site,
when pre and post construction works or minor painting and coating work
is carried out, approved paint thickness measuring devices, coating
'holiday' detectors, continuity detectors and other devices as required by
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HPAA for the determination of the acceptability of painting and protective
coating work being carried out, along with qualified technicians competent
to operate such measuring/devices and detectors.
e)

The contractor shall furnish all Equipment and Materials and fresh water or
compressed air necessary for the cleaning out and pressure testing of
pipework, tanks and vessels. The contractor shall be responsible for the
disposal of all test water after use.

4.123.3

Visual Inspection

a) All Materials and the WORK are subject to visual inspection for surface
defects, etc.
b) All welds shall be inspected in accordance with - SPECIFICATIONS, CODES and
STANDARD
PROCEDURES.
HPAA
TECHNICAL
SPECIFICATIONS,
INTERNATIONAL CODES and STANDARD HPAA PROCEDURES. Welds found
to be outside the defect tolerance of the specifications shall be repaired or
replaced to the satisfaction of HPAA and at the contractors expense.
c) Complete records of all weld inspections including weld radiographs
shall be maintained by the contractor and furnished to HPAA at the
request of HPAA.
d) All Washing Out/Flushing shall be done in accordance with SPECIFICATIONS, CODES and STANDARD PROCEDURES HPAA TECHNICAL
SPECIFICATIONS,
INTERNATIONAL
CODES
and
STANDARD
HPAA
PROCEDURES..
e) Washing out shall be carried out with all valves removed. On completion
of washing out, certain valves and other fittings will be reinstated, as
directed by HPAA.
f) All pipework of diameter two (2) inches and larger shall be adequately
washed out using a low pressure, high volume flow of fresh water, on
completion of installation.
g) All pipework system that cannot be contaminated with water may be
flushed/cleaned using air.
h) Strainers shall be installed at appropriate points and/or as directed by
HPAA to protect fittings, pumps, etc.
4.123.4

Pressure Testing

a) All pipework and valves shall be pressure tested in accordance withSPECIFICATIONS, CODES and STANDARD PROCEDURESHPAA TECHNICAL
SPECIFICATIONS,
INTERNATIONAL
CODES
and
STANDARD
HPAA
PROCEDURES. as per clause 4.138.5.

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b) The contractor shall be responsible for properly preparing the WORK for
pressure testing. Such preparation shall include, but not be limited to, the
following:c) Reviewing the drawings to ensure that adequate vents, drains and
spades are provided in order to test the test the WORK in accordance with
- SPECIFICATIONS, CODES and STANDARD PROCEDURES, HPAA TECHNICAL
SPECIFICATIONS,
INTERNATIONAL
CODES
and
STANDARD
HPAA
PROCEDURES even though such vents, drains and spades may not be
specifically shown on the contract drawings. any testing required by this
contract in writing and in schedule form, a procedure for testing the
WORK, to include, but not limited testing procedures, test pressures
indicated on a marked-up flow scheme, time schedules, diagrams, and
proposal for installation of any additional vents, drains, spades, and relief
valves which may be require do, d) During the whole period of testing of
the WORK, the contractor shall provide and install to the satisfaction of
HPAA calibrated and accurate test gauges and recorders and all other
necessary Equipment such as additional safety relief valves, together with
associated pipe and fittings, and all spectacle spades, plugs, etc. required
in order to carry out pressure testing in accordance with - SPECIFICATIONS,
CODES & STANDARDS PROCEDURES. STANDARDS PROCEDURES.HPAA
TECHNICAL SPECIFICATIONS, INTERNATIONAL CODES and STANDARD HPAA
PROCEDURES.
e) All instruments shall be removed or isolated during pressure testing. All
control valves shall be removed during pressure testing.
f) Piping joints (flanged, threaded, and welded) shall be left unpainted and
un-insulated, until pressure testing has been completed.
g) Upon completion of hydrostatic pressure testing, the contractor shall
drain and dry all lines, vessels and equipment.
h) The contractor shall remove all temporary facilities installed by the
contractor once testing is completed, to the satisfaction of HPAA. Tests
shall be witnessed by HPAA and records of all tests shall be furnished to
HPAA.
4.123.5

List of Codes and Standards

Contractor need to follow the standards below or all relevant standards

upon completion of this project,
a) ASME IX : Welding and Brazing Qualifications
b) ASME B31.3 : Process Piping
4.123.6 Equipment commissioning / Pre Set Up Safety Review (PSSR) / Post Event
Review (PER).

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a) The contractor together with HPAA shall do PSSR before commissioning
the Acid/OreAcid Ore Slurry Lines.
b) The contractor need to rectify the entire item resulted in PSSR that is in
contract.
c) The contractor shall commission Acid/OreAcid Ore Slurry Lines once the
entire main job scope completed together with HPAA representative.
d) The contractor shall carry out PSSR and PER with HPAA upon project
completion.
4.134General
4.134.1
The contractor shall produce ITP (Inspection Test Plan) for inspection
at contractors workshop.
4.134.2
Gas test will be performed by HPAA competent AGT every 4-hours
interval and subject to change based on Responsible Engineers discretion.
4.134.3
Power socket outlets are provided in the form of 3pin and 5pin
industrial socket. Conventional 3 pin plug are prohibited from usage in
HPAA site. Hence contractor shall make sure the distribution boxes to be
used are well installed with the industrial type with short circuit or fault
protection.
4.134.4
Each electrical equipment/appliances, diesel generator set,
compressor and not limiting as stated which required to safely execute this
work shall be supplied by the contractor and inspected by HPAAs
dedicated inspector prior to usage in HPAA site.
4.143.5
The contractor shall perform this job within office hours and any job
for around the clock (24 hours/ day) in-order for fast completion need to
get approval by duty engineer.
4.134.6
Flexibility of shift arrangement at the contractors preference but
the contractor shall ensure that work supervisors and safety officers to be
allocated in every-shift.
4.143.7
Scaffolding arrangement shall be manage by contractor and cost
will be charged under contractor. Contractor shall hire internal HPAA
scaffold contractor for this project. Please refer 4.9 for ladder and scaffold
requirements.
4.134.8
Any lifting works shall be planned and endorsed by qualified lifting
engineer. The contractor shall submit all the lifting procedure and lifting
study to HPAAs engineer for review. Please refer to item 4.10 for lifting
operations.
4.134.9
Any Hot Work activities shall follow the HPAA hot work procedures
as minimal requirement.
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TK42218 ACID/OREACID ORE SLURRY LINES RENEWAL YEAR 2016

4.134.10
These general scopes are the minimum requirement for this
project and contractor shall to refer the details procedure as attached in
next pages.
4.134.11
Contractor is highly responsible to ensure all workmen follow
HPAA safety procedure and ensure the ZERO HARM objectives achieved
along working in HPAA Plant.
4.134.12
Any removal or displacement of structural, platform, roofing
or existing machine must to be under contractor responsibility. Contractor
is responsible to prepare and submit to HPAA engineer the method of
replacement for every section of jobs and verified by competence person.
4.134.13
Contractor shall submit the details of method of repairs,
inspection plan, certifications such welding or others related documents to
HPAA project engineer for review. Contractor responsible to brief to the
HPAA and need consideration for any changes required.
4.134.14
Contractor shall to prepare scope of work for transportation,
housekeeping, generals workers activities (dismantle, re-installation, new
installation, of drier inlet shell and others components.
4.134.15
Contractor shall to prepare the scope of work for the whole
project includes, calculation, fabrication, construction, testing, alignment
and commissioning.
4.134.16
Contractor shall submit valid welding qualification test (WQT),
welding procedure specification (WPS), procedure qualification record
(PQR), valid 6G competence welder certifications and others related
documents.
4.134.17
The contractor shall prepare, procure and supply all materials
that are going to be used for electrical apparatus complete with
manufacturing data record, material certificates and other related
certificates.
4.134.18
All bolting installation for attachment shall comply with HPAA
Standards which includes material specification, torque values and
dimensional requirements.
4.134.19
Contractor shall provide site supervision to ensure full compliance of
standards and safety.
4.134.20
Should there any metal repair identified on the steel structures, the
contractor shall inform HPAA representatives for further actions by HPAA.
4.134.21

No sub-contracting without HPAA approval.

4.134.22
The contractor shall to prepare and to submit the Safe Work Method
Statement (SWMS) and Hazards Identification, Risks Assessment and Risks
Control (HIRARC) before carrying out any job.
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TK42218 ACID/OREACID ORE SLURRY LINES RENEWAL YEAR 2016

4.134.23
approval.

Any usage of chemical substances for the WORKS shall obtain HPAA

4.134.24
Contractor to gather all scrap metal upon completion of daily work
and move it to designated area in HPAA premise for HPAA record.
4.134.25
Contractor to ensure all the nearby equipment is safe from the
repair/ maintenance work. Any damage to the equipment as the result of
contractors work, the repair cost will be charged to the contractor.
4.134.26
Contractor to ensure all lifting gears is in good condition and safe
from any damages. Contractors shall provide third party calibration
certificate/ load test certificate for all lifting gears especially lifting slings.
HPAA has the rights to reject any lifting gear and stop work due to no
compliance shall be borne by the contractor.
4.145Delivery
4.145.1
Contractor shall prepare scope of work for delivery all equipment
and materials from contractor yard to HPAA site.
4.145.2
Contractor shall submit the schedule for transportation and verify
by HPAA engineer.
4.145.3
Contractor shall responsible to ensure all machineries and electrical
tools inspected at HPAA workshop upon the delivery.
4.145.4
Contractor is responsible to deliver the materials and equipment to
HPAA site safely.
4.145.5
Contractor awarded shall deliver the project within the
approved schedule agreed by the HPAA and contractor. Contractor has
rights to start the fabrication work on time after received the Purchase
Order. HPAA has rights to amend any schedules before or during the
executions.
4.156Tender Requirements
The contractor shall supply the following information with the bid (where
applicable & practicable):

Cover letter

Propose scope supply

Propose of manpower
a) Proposed project team organization chart
b) Proposed construction team organization chart
c) Proposed manpower loading

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TK42218 ACID/OREACID ORE SLURRY LINES RENEWAL YEAR 2016

d) Curriculum Vitae (CV) of manpower and any other valid certificates of
competency

Propose list of materials and consumable

Preliminary project schedule (MS Project)

a) Proposed shop fabrication work schedule
b) Proposed site installation works schedule

Company EHSMS (environment, health, safety and management system)

a) EHSMS Manual
b) SWMS (Safe Work Method Statement)
c) EHS performance (past 3 years)

Complete company profile with financial statement (for Commercial

Submission only).

List of major company serviced beside Huntsman P&A Asia Tioxide (M) Sdn
Bhd and related past project references c/w reference contact detail

Preliminary Safe Work Method Statement (SWMS) and hazard

identification, risk assessment and risk control (HIRARC) for each specific
work activities.

Schedule and specification of all equipment proposed.

Itemized list of all variations from this specification.

Submit MSDS and TDS for painting system.

As part of quality assurance, Contractors are required to submit ITP in

order to assist the quality assurance works. The completed ITP after review
by HPAA shall be among the final documentation deliverables to HPAA.

List of all proposed sub-contractors, company profile and their organization

chart.
Copy of WPS, WQT and PQR.

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TK42218 ACID/OREACID ORE SLURRY LINES RENEWAL YEAR 2016

Insurance
a) Third party liabilities
b) Workmen compensation
c) Erection all risk

A detailed cost breakdown (Bill of Quantity with price for Commercial

proposal. For every lump sum (LS) items, Contractor needs to provide the
breakdown cost showing how they come out with the prices).

A detailed cost breakdown (Bill of Quantity without price for technical

proposal)

Please use index divider for each section to ease the reference process and
ensure all tender requirements are followed.
The contractor shall provide:
a) One (1) original and one (1) copy of Commercial Bid Document
and
b) One (1) original, one (1) copy and (1) soft copy in CD of Technical
Bid Document
All documents are to be in sealed envelope marked with:
a) Title of the Project
b) Original or copy of Commercial/ Technical Bid
Attention:

Procurement Lead
Tioxide (M)Hunstman P&A Asia Sdn. Bhd.
Teluk Kalong Industrial Area,
P.O. Box 29,
24007 Kemaman,
Terengganu Darul Iman.
Closing Date: ________________________
All bids must reach Commercial Service Section on or before closing date.
Submission after closing date will be rejected.

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4.176Schedule Overview
Project milestones:
Issue of Tender

: Estimated on 24th JuneOct 2016

Close of Tender

: Estimated on 15th July Nov 20165

Purchase order release

: Estimated on 29th July Nov 20165

Commencement of Work

: Estimated on 22nd September Dec 20165

: TBA by HPAA (Estimated on Estimated on 5th

Commencement of Work at Site

OctoberFeb 20175)
Project Completion

: Estimated on Mac 1st November 2015

This is the general overview of this project. The vendor shall submit detail
schedule with all major activities in a separate plan along with the quotation.
Advise to produce plan in Microsoft Project 2003 edition (soft and hard copy).
It is recommended that the contractors visit the site to confirm
existing conditions prior to submission of the Proposal. HPAA have right
to amend if necessary. Claims for additional work to ascertain and document
existing conditions, other than stipulated in this document, will not be
acceptable. Site visits can be arranged with the following personnel:
Chooi Jia Hoong
Hunstman P&A Asia Tioxide (M) Sdn. Bhd.
Teluk Kalong Industrial Area,
P.O. Box 29,
24007 Kemaman,
Terengganu Darul Iman.
Tel: 09-8628 728688
JiaHoong.Chooi@jacobs.com
Bidders shall submit his quotation/proposal.
4.187Guarantee
4.178.1

Workmanship and material

The contractor shall guarantee the equipment against faulty workmanship

or materials and failure from normal usage for twelve (12) months after
commissioning or (18) months after delivery to site whichever is earlier.
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TK42218 ACID/OREACID ORE SLURRY LINES RENEWAL YEAR 2016

4.178.2

Rectification of defect

If the material supplied or the work done is defective and substandard,

then the contractor shall carry out such modifications and/or replacements
that are necessary to make good the performance as quickly as possible.
All cost of modifications, repair, delivery or parts shall be borne by the
contractor and if the contractor fails to rectify the defects after 2 weeks of
official notice, HPAA has all the right to appoint a 3rd party to undertake
the rectification and all the related cost for the rectification works will be
back charged to the contractor .The parts replaced or modifications done
shall be guaranteed for twelve (12) months.
4.189System Documentation
4.189.1

Final documents should comprise of all the below list:

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)

MSDS/ Mill certificate for all the material used

Materials valid date
Materials inspection report
Repair procedure
Inspection report
Inspection Tools calibration cert
Non Destructive Examination (NDE) reports
Testing and commissioning report
Handover certificate
SWMS and HIRARC complete document
Manpower loading and name list with competency certificate
Copy of manpower medical report examined by Occupational Doctor
(DOSH)
m) Quality control plan/ Inspection and Test Plan (after award)
n) Punch list
o) Detail milestone/ work program for the complete refurbishment works
p) Copy of WPS, WQT and PQR
q) Isometric drawings and as built drawings
4.198.2

Document Requirements shall to meets:

a) The International System (S.I) shall be used for all measurements in
documents and drawings
b) Language shall be English, unless otherwise specified
c) All drawings shall be produced in either size A1, A3 or A4 only. All
calculations shall be submitted in A4 paper only
d) All documents with AutoCAD version 14 and above, shall be saved
using CD and submitted along with the Final Documentation

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